And Flow Devices - Carrier 19XR Start-Up, Operation And Maintenance Instructions Manual

chiller operation, load conditions during operation, and the
condition of the oil and the lubrication system. Excessive
bearing wear can sometimes be detected through increased
vibration or increased bearing temperature. If either symp-
tom appears, contact an experienced and responsible service
organization for assistance.
Inspect the Heat Exchanger Tubes and Flow
Devices
COOLER AND FLOW DEVICES — Inspect and clean the
cooler tubes at the end of the first operating season. Because
these tubes have internal ridges, a rotary-type tube cleaning
system is needed to fully clean the tubes. Inspect the tubes'
condition to determine the scheduled frequency for future
cleaning and to determine whether water treatment in the
chilled water/brine circuit is adequate. Inspect the entering
and leaving chilled water temperature sensors and flow de-
vices for signs of corrosion or scale. Replace a sensor or
Schrader fitting if corroded or remove any scale if found.
CONDENSER AND FLOW DEVICES — Since this water
circuit is usually an open-type system, the tubes may be sub-
ject to contamination and scale. Clean the condenser tubes
with a rotary tube cleaning system at least once per year and
more often if the water is contaminated. Inspect the entering
and leaving condenser water sensors and flow devices for
signs of corrosion or scale. Replace the sensor or Schrader
fitting if corroded or remove any scale if found.
Higher than normal condenser pressures, together with the
inability to reach full refrigeration load, usually indicate dirty
tubes or air in the chiller. If the refrigeration log indicates a
rise above normal condenser pressures, check the condenser
refrigerant temperature against the leaving condenser water
temperature. If this reading is more than what the design dif-
ference is supposed to be, the condenser tubes may be dirty
or water flow may be incorrect. Because HFC-134a is a high-
pressure refrigerant, air usually does not enter the chiller.
During the tube cleaning process, use brushes specially
designed to avoid scraping and scratching the tube wall. Con-
tact your Carrier representative to obtain these brushes. Do
not use wire brushes.
Hard scale may require chemical treatment for its pre-
vention or removal. Consult a water treatment specialist
for proper treatment.
Water Leaks —
The refrigerant moisture indicator on
the refrigerant motor cooling line (Fig. 2) indicates whether
there is water leakage during chiller operation. Water leaks
should be repaired immediately.
The chiller must be dehydrated after repair of water leaks.
See Chiller Dehydration section, page 51.
Water Treatment —
Untreated or improperly treated
water may result in corrosion, scaling, erosion, or algae. The
services of a qualified water treatment specialist should be
obtained to develop and monitor a treatment program.
Water must be within design flow limits, clean, and treated
to ensure proper chiller performance and reduce the
potential of tube damage due to corrosion, scaling, ero-
sion, and algae. Carrier assumes no responsibility for
chiller damage resulting from untreated or improperly
treated water.
Inspect the Starting Equipment —
ing on any starter, shut off the chiller and open all discon-
nects supplying power to the starter.
The disconnect on the starter front panel does not de-
energize all internal circuits. Open all internal and
remote disconnects before servicing the starter.
Never open isolating knife switches while equipment is
operating. Electrical arcing can cause serious injury.
Inspect starter contact surfaces for wear or pitting
on mechanical-type starters. Do not sandpaper or file
silverplated contacts. Follow the starter manufacturer's
instructions for contact replacement, lubrication, spare parts
ordering, and other maintenance requirements.
Periodically vacuum or blow off accumulated debris on
the internal parts with a high-velocity, low-pressure blower.
Power connections on newly installed starters may relax
and loosen after a month of operation. Turn power off and
retighten. Recheck annually thereafter.
Loose power connections can cause voltage spikes, over-
heating, malfunctioning, or failures.
Check Pressure Transducers —
pressure transducers should be checked against a pressure
gage reading. Check all eight transducers: the 2 oil differ-
ential pressure transducers, the condenser pressure
transducer, the cooler pressure transducer, and the waterside
pressure transducers (consisting of 4 flow devices: 2 cooler,
2 condenser).
Note the evaporator and condenser pressure readings on
the HEAT_EX screen on the CVC (EVAPORATOR PRES-
SURE and CONDENSER PRESSURE). Attach an accurate
set of refrigeration gages to the cooler and condenser Schrader
fittings. Compare the two readings. If there is a difference in
readings, the transducer can be calibrated as described in the
Troubleshooting Guide section. Oil differential pressure (OIL
PUMP DELTA P on the COMPRESS screen) should be zero
whenever the compressor is off.
Optional Pumpout System Maintenance —
pumpout unit compressor maintenance details, refer to the
06D, 07D Installation, Start-Up, and Service Instructions.
OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE —
Use oil conforming to Carrier specifications for reciprocat-
ing compressor usage. Oil requirements are as follows:
ISO Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Carrier Part Number . . . . . . . . . . . . . . . . . . . . PP23BZ103
The total oil charge, 4.5 pints (2.6 L), consists of
3.5 pints (2.0 L) for the compressor and one additional pint
(0.6 L) for the oil separator.
Oil should be visible in one of the compressor sight glasses
during both operation and at shutdown. Always check the
oil level before operating the compressor. Before adding or
changing oil, relieve the refrigerant pressure as follows:
1. Attach a pressure gage to the gage port of either com-
pressor service valve (Fig. 33).
68
Before work-
Once a year, the
For